25 Oct 2019 18:28 (GMT)

DS Smith Plastics, Worldwide Dispensers

Replaces One-Way Packaging with Reusable
Container Stackabox™ Hybrid to Supply
Moulded Taps to Clients
DS Smith Worldwide Dispensers, a leading supplier of injection moulded
plastics taps for the beverage industry has replaced their entire supply
chain of one-way packaging with reusable and collapsible dispensing
containers.
The challenge
DS Smith Plastics, Worldwide Dispensers business segment has been looking to improve efficiencies
in their supply chain by replacing one-way packaging used to supply moulded parts to their clients
with reusable containers.

In close cooperation with the client they defined that the solution had to be compatible with top
dispensing systems, needed a removable cover with lock and the possibility to hold one plastic bag
per box to pack the parts. The previous one-way packaging could hold only around 600 pieces per
box. One pallet could hold 20 boxes, meaning one truck with 25 pallets could transport 300,000
pieces per truck. To make logistics more efficient and to save costs, Worldwide Dispensers looked
for a more efficient alternative and found one within their own plastics division.

The approach
Stackabox™ Hybrid manufactured by their Injection Moulding business segment was designed to
transport, store and dispense fragile moulded bottles, closures and taps. In addition, Stackabox
Hybrid is durable, reusable and collapsible when empty, making it the ideal solution that can be
utilised throughout the entire production process. The removable cover can be locked, and the box
has the possibility to hold a liner. The top dispensing is suitable for a wide range of products.

The result
Stackabox™ Hybrid foldable containers are compatible with top dispensing systems but can be
integrated in any dispensing system, such as base dispensing, allowing for more flexibility for the
future. The container fits perfectly with DS Smith Plastics, Worldwide Dispensers Supply Cycle
logistics’ needs. Only one Stackabox Hybrid can hold 4,200 moulded pieces and thanks to an optimal
load of truck, 26 Stackaboxes can be stacked 3 high, allowing approx. 330,000 pcs per truck. The
solution offers multiple advantages: it reduces handling costs, saves costs, fast ROI and reduces the
number of trucks on the road with 10%, reducing CO² emissions significantly. The highly efficient
fold ratio minimises warehouse storage costs. The durable construction with smooth internal
surfaces ensures ease of cleaning, providing maximum hygiene for the storage of the caps and the
easy integration of a liner allows for easy packing. Stackabox Hybrid is fully recyclable after it’s useful
long life of at least 500 return trips.